Product Life Cycle Support (PLCS)Managing Product Support Information from Concept to Disposal

Setting the standard for product support

Howard Mason (BAE SYSTEMS)Chairman of the Board, PLCS inc

2PLCS Inc. (c) 2002

Objectives of the day

Overview of the PLCS initiativeScope and featuresStatus

Opportunities for exploitationImplementation plans

VendorsSuppliersCustomers

The way ahead for PLCSQuestions?

3PLCS Inc. (c) 2002

The PLCS Initiative

The Business Context Overview of PLCS

VisionScopeDeliverablesCapabilities

Status

4PLCS Inc. (c) 2002

Setting the Business ContextBusiness Drivers

Reduced Cost of OwnershipUsers of products are seeking improved availability, reliability, maintainability and lower cost of ownership.

Protect investment in product dataUsers of information systems want more open platforms to reduce IT costs and ensure longevity in use of information

Sustainable Business GrowthCompanies are seeking to make money through the life cycle support of their products to improve profits, improve quality and be more competitive

5PLCS Inc. (c) 2002

Setting the Business ContextDigital Product Data has become a valuable business asset

New Business OpportunitiesLeading manufacturers are ‘going downstream’ to generate additional revenue from supply of lifecycle support services

Product Lifecycle ManagementIncreased focus on managing information throughout the product lifecycle – Concept to DisposalBusinesses are focusing on total cost of ownership, as product life cycles increase and products become more expensive to maintain

Extended EnterpriseIncreasingly complex business networksKnowledge workers need to share information in real timeNot practical to adopt common system mandateInternet technology changes everything

6PLCS Inc. (c) 2002

Setting the Business ContextRequirements of the Extended Enterprise

Extended enterprises are formed to meet project specific requirements

Partners may differ from project to projectDifferent partners are likely use different systemsCompanies want a common way to exchange digital product dataConfiguration Management becomes a key enabler for information exchangeSuppliers want a unified approach from Prime Contractors and OEMsInternational collaboration demands product data exchange and sharing across many organizationsWorldwide operation demands a worldwide standard

Program ManagerProgram Manager SalesSalesMarketingMarketing

EngineeringEngineering SupportSupportMfg.Mfg.

Project ZProject Z

Product Team 2

Product Team 2

Product Team 1

Product Team 1

Project YProject Y

Project XProject X

Supplier ASupplier A

Supplier BSupplier B Supplier CSupplier C

PartnerPartner

FIREWALLFIREWALL

7PLCS Inc. (c) 2002

Setting the Business ContextConfiguration Management is a major challenge

Multiple product viewsMajor problems keeping information to operate and maintain a product aligned to actual product configuration through lifeMajor problems linking support information to product informationSoftware applications use proprietary data standards and are often difficult to integrateInconsistent data definitions

CustomerRequirements

CustomerRequirements

Conceptand

Assessment

Conceptand

Assessment Demonstrationand

Manufacture

Demonstrationand

ManufactureIn Service

and Disposal

In Serviceand

Disposal

Feedback

As ManufacturedConfiguration

As PlannedConfiguration

As DesignedConfiguration

Feedback

As MaintainedConfiguration

8PLCS Inc. (c) 2002

Setting the Business ContextLimitations with current standards (1998)

Transaction CentricDefence: AECMA 2000MCommercial: ATA Spec 2000, Edifact, ANSIx.12

Content CentricCAD Models/PDM: ISO 10303 (STEP)Configuration Management (EIA 649+)Logistic Support Analysis: MIL-STD-1388, Def-Stan 00-60

Presentation Centric AECMA Spec 1000DATA Spec 100

Current (1998) standards for product support information:Address individual processes, not life cycle managementUse different technologiesHave gaps, conflicts and overlaps. Predate the internet age

9PLCS Inc. (c) 2002

Setting the Business ContextAvailable capabilities - ISO STEP

STEP is an established international standard for the exchange, integration and sharing of product data

GeometryProduct structureManufacturing interfacesDrawings

STEP Release 2 covers new functions:Finite Element AnalysisPrinted Circuit AssembliesWiring loomsMechanical DesignConstruction industry

XML for the Web

10PLCS Inc. (c) 2002

Eurofighter TyphoonSTEP in service

Structural build work share

37.5% BAE SYSTEMS

19.5% ALENIA

30% EADS-Germany

13% EADS-CASA

Nat

iona

l and

exp

ort c

usto

mer

s

Concurrent product development

Supp

liers

Commonsupplier

base

Four assembly

lines

11PLCS Inc. (c) 2002

Eurofighter PDM Data ExchangeSTEP in service

BAE SYSTEMS

Alenia

EADS-D

EADS-CASA

Partners use different PDM systemsProductManager (BAE SYSTEMS, Alenia), MetaPhase (EADS-Germany)Optegra (EADS-CASA)

Exchange required to supportConfiguration managementProduct Structure release

12PLCS Inc. (c) 2002

Setting the Business ContextSTEP in service

Supplier interface for Lockheed MartinConfiguration Management and Digital Pre-Assembly

exchange at Boeing - RR, GE and P&WInterface between A380 and its enginesIBM's global e-procurement design data exchangeSolid model exchange for Electric BoatUS and UK Navy RAMP programmesJapanese SCADEC programme for the construction industryFord CAD/PDM data integrationNASA Engineering information

13PLCS Inc. (c) 2002

OverviewImagine the opportunities if …

Configuration management information was always accurate, up to date and immediately accessibleMaintenance information was precisely tailored to the work to be doneSpares and inventory costs were minimized through vendor involvement in an integrated supply chainIn-service feedback was accurate, meaningful and readily available to product designers and support managersChange was easy to manage

14PLCS Inc. (c) 2002

OverviewThe Key Business Problem

How to keep the information needed to operate and maintain a product aligned with the changing product over its life cycle?

Tools

TestEquipment

SupportFacilities

Consumables

Software

Transportation

Spares

StorageRequirements

Training

Product DefinitionInformation

MaintenanceSchedules

Productin FocusProductin Focus

FeedbackFeedback

15PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Membership

FinnishDefence Forces

16PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)The Initiative

A joint industry and government initiative to accelerate development of new standards for product support information

An international project to produce an approved ISO standard within 4 years; commenced November 1999

PLCS will ensure support information is aligned to the evolving product definition over the entire life cycle

PLCS extends ISO 10303 STEP - the STandard for Exchange of Product model data

www.plcsinc.org

17PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)The Vision

Scope of STEP Today

Shared Data

Product Representations

Product Performance

Product Structure

Support Performance

Change Directives

Support Environment

Failure Analysis

Maintenance Analysis

Task Resource Data

Life Life Cycle Cycle DataData Maintain/DisposeMaintain/DisposeQueryQuery

Derived Disposable Derived Disposable DataData

UseUseRespond

Respond

Support and Operational Feedback

Standard Standard Commercial Commercial TransactionsTransactionsFeed and

Feed and

ExtractExtract

18PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Typically complex systems environment – point to point integration

7.FMECA

2.Maintainers

ViewingTool

3.StockMgmt

4.MaintenanceManagement

10IETM

11Parts

Supplier Database

12 Depot Maint

Mgmt

13.Distribution,

Transportation

14 Defects & FailureReporting

LSA Data

5.RequirementsManagement

LSA Data

Support Data

CM Data

Support Data

Part Data

CM Data

CM DataCM Data

Defects and

FailuresMaintenance

Mgt Data

DesignData

DistributionData

Tech Pubs Data

1.Support

Data

CM Data

FMECAResults

Operational Objectives

Functional Requirements 9.Product

Data

6.LSAR

8.CAD

LSA Data

Support Data

19PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)PLCS will enable cost effective information exchanges

2.Maintainers

ViewingTool

4.MaintenanceManagement

1.Support

Data

3.StockMgmt

5.RequirementsManagement

7.FMECA

6.LSAR

LSA DataMaintenanceMgmt Data

FMECAResults

MaintenanceMgmt Data

Support data Part data Functional Req.

PLCS compliant information exchangesPLCS compliant information exchanges

TechPub Data

MaintenanceMgt Data

Defects& Failures

Design Data Design data DistributionData

Parts Data

11Parts

Supplier Database

12 Depot Maint

Mgmt

13.Distribution,

Transportation

14 Defects & FailureReporting

9.Product

Data

8.CAD

10IETM

In future, support system integration will be easier to implement

20PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Extended Enterprise enabled by Internet technology

Extended Enterprise ofOEM’s, Customer, Partners

and Suppliers

Enterprise Integrationthrough dedicated networks

Domain specific information systems

(e.g. CAD, MRPII, Planning)

Dep

tEn

terp

rise

Cus

tom

ers

Part

ners

Tier

1

Supp

liers

Tier

2Su

pplie

rs

Exte

nded

Ent

erpr

ise

Inte

grat

ion

Product Life Cycle

Internet-based architecture and federated data models make possible implementations involving thousands of users across many sites

Concept Assessment Demonstration Manufacture In-Service DisposalOperational Feedback

PLCSDomain

Define and implement the support solution, maintain the product configuration

Product Lifecycle Management (PLM)

21PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Extended Enterprise – Importance of PLCS

Dep

tEn

terp

rise

Cus

tom

ers

Part

ners

Tier

1

Supp

liers

Tier

2Su

pplie

rs

Exte

nded

Ent

erpr

ise

Inte

grat

ion

Product Life Cycle

C A D M In-Service D

PLCS DomainPLCS Domain

Design forSupportability

Design forSupportability

In Service Support andOperational Feedback

In Service Support andOperational Feedback

Typically 25 – 50 years Operational Life5 – 10 years

When set against a timeline – the picture looks more like this!

22PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Example: PLCS for MOD and Defence Contractors

Multiple Contracts with UK Defence Contractors

CRISP

MRC

DR4LITS

OASIS Etc …

MOD Databases for Product Support

Project specific ‘Point to Point’ interfaces to be developed and maintainedISO 10303 STEP, AP 239 (PLCS)ISO 10303 STEP, AP 239 (PLCS)

LPD(R)

EurofighterEtc …

Astute AstuteTrent 800

RB 199

Etc … Etc …

WAH-64 ApacheEH 101 Merlin

Bowman

SupportContractor

23PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Goals

PLCS Standard:Improve product availabilityReduce operating, support and maintenance costsImprove quality and accessibility of Product Life Cycle Support information

PLCS, Inc:Accelerate technical development of the ISO standardsEncourage early implementation commercial software vendorsEncourage early industry participation in the development and testing of the standard

24PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Deliverables

A new vision for life cycle supportA terminology dictionaryAn illustrative process model (Application Activity Model)A large data model, standardised through ISO (AP239)An extensible set of data exchange standards (constrained subsets of AP239, with implementation guidance)Improved capability to tailor or extend the data model or exchange sets using “reference data” (with maximum re-use from current standards)A standardised interface to one (or more) transaction standards/systems .. (ebXML, Exostar, 2000M?)

25PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Capabilities enabled by PLCS – ISO 10303 AP 239

Product DescriptionCapability to define product requirements and configuration, including relationships between parts and assemblies in multiple product structures (as-designed, as-built, as-maintained)Work ManagementCapability to request, define, justify, approve, schedule and capture feedback on work (activities) and related resources.Property, State and BehaviourCapability that describes and captures feedback on product properties, operating states, behaviour and usageSupport Solution and EnvironmentCapability to define the necessary support for a given set of products in a specified environment and to define support opportunity, facilities, personnel and organizations

AP 239Capabilities

AP 239Capabilities

26PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Unique Value Proposition

International Standard for product support information - based on ISO 10303 STEP (AP 239)Complete product lifecycle – from concept to disposalSingle source of assured product and support informationData independence - Processes, Systems, Format Interoperability across enterprises and systems through:

Standardization of semantics for product supportIntegrated suite of data models for data exchange and information sharingUtilization of ISO STEP standards, methods and tools (incl XML/XSLT)

Extensibility and tailoring through the use of Reference data libraries

Customers, Contractors and Software VendorsCustomers, Contractors and Software Vendorsworking together to develop and implementworking together to develop and implement

a neutral data exchange standard for product supporta neutral data exchange standard for product support

27PLCS Inc. (c) 2002

Current situation (November 2003)

Activity Model published (available to all)1750 requirements allocated to ~130 modulesModule development completed:

PDM Modules are now stable as ISO Technical SpecificationsAll PLCS modules unanimously accepted as ISO Technical SpecificationsAP239 information model available

Draft International Standard ballot for Application Protocol due to start in November 2003Development of first eight Data Exchange Sets under wayLaunch events in September in Scandinavia, US and UKFuture organisation in place - transition under wayImplementation activities are gaining momentum in UK, Norway, Sweden, Finland and US

28PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Customer Pull

MOD Announcement - 2000-11-14 Defence Contracts InternationalThe MOD now specifies the electronic exchange of product model data in many of its contracts. In January 2003, the Department will introduce a new policy that, wherever this is required, IS 10303, Standard for the Exchange of Product Model Data (STEP) will be adopted as the uniform standard of preference.

STEP is a standardised way of structuring information to reflect the needs of supported business process. It provides implicit quality assurance to improve reliability and eliminate transcription errors and is based upon sound computer science principles, which aim to make the standard extensible and not technology limited, hence maximising longevity. STEP provides a mechanism for handling archive, and over time, legacy data.

Early parts of the International Standard were released in 1993 and development has continued through the implementation of its Application Protocols. STEP is already in use in the aerospace industry (including Boeing, BAE SYSTEMS, and Rolls Royce), the automotive industry (including BMW, Mercedes Benz and Volkswagen) and in the US and UK defence departments (including the Rapid Acquisition of Material Parts -RAMP - initiative).

Between now and January 2003, the MOD and appropriate industrialpartners will be conducting a number of pilot implementations of the standard to develop the necessary expertise

Product Life Cycle Support (PLCS)Managing Product Support Information from Concept to Disposal

Supplementary slides

30PLCS Inc. (c) 2002

Product Life Cycle Support (PLCS)Inputs to the Initiative

NATOPilot

Project #1

NATOPilot

Project #1

PLCSISO 10303

AP239

PLCSPLCSISO 10303ISO 10303

AP239AP239

Mil SpecCM2549

Mil SpecCM2549

ATAEffectivity

ATAEffectivity

AP208AP208

POSC/CaesarPOSC/Caesar

FMVCTG2FMVCTG2

AP203AP203

ISOTC184/SC4

WG3/T8PWI

ISOTC184/SC4

WG3/T8PWI

PDMSchema

PDMSchema

AP 233AP 233

PLIBPLIB

Def Stan00-60

Def Stan00-60

NCDMNCDM

ALISALIS

AECMA1000D2000M

AECMA1000D2000M

ISO15288ISO

15288OMGOMG

STEPSTEP

Mil Spec1388

Mil Spec1388

+ Others